Refractory Coating Technology: A Review
Coating Technology
Keywords:
refractory coating, casting, refractory material, characterisation, binder, additiveAbstract
Application of refractory coatings in foundry is very essential as they significantly enhance the surface finish of castings. Coatings applied on mould cavities, cores or patterns (as in lost foam casting) fill the tiny spaces in between the mould sand particles, solidify and render the mould surfaces smooth before pouring the liquid metal. The resulting enhancement of the surface finish of the casting has brought about an indisputable conclusion that there can be no acceptable casting without the application of refractory coatings. The casting production is considered as a backbone and influencer of the development of global economy as the level of industrialisation in each country is a reflection of the practical attention given to casting production. The demand for casting products has been on the increase over the years leading to increase in demand for refractory coatings. The indispensability of refractory coatings in casting production necessitates understanding the nitty-gritty of coating production technology which expectedly calls for a comprehensive review. The information provided in this study would undoubtedly serve as a handy summary of refractory coating production in relation to casting surface finish enhancement.
References
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Pacyniak, T. The Effect of Refractory Coating Permeability on the Lost Foam Process (2008). Archives of Foundry Engineering, 8(3): 199 - 204.
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Aftab, A. Qureshi, M. I., Mujahid, m. and Khalid, S. Effect of different Coatings on the Surface Finish and hardness of manganese steel castings ( 2019 ).
Yekeler, M., Ulusoy, U. and Hicyilmaz, C. Effect of Particle Shape and Roughness of Talc Mineral around by Different Mills on the Wettability and Floatability (2004). Powder Technology, 140(12), pp. 68-78.
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Baker, S. G. Evaluating Refractory Coatings: a Practical Approach (2002). Modern
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Winardi, L. and Griffin, R. D. Effects of Coating Drying Methods on LOI, Gas Evolution and Core Permeability. AFS Transactions Paper, Vol. 08-047, 2008.
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http://amc.aticorp.org
Chen, X. and Penumadu, D. Permeability Measurement and Numeri Modelling for
Refractory Porous materials (2008). Shaumburg IL: AFS Transactions, American Foundry Society, US. Unpublished.
Anderson, W. A. Permeability Relationships Using Darcy Permeability, Vacuum Decay, Pressure Decay and Pore Size Distribution Methods on Graphic Materials (1966). Carbon, 4(1): 107 – 114.
Sogabe, T., Inagaki, M. and Ibuki, T. Coating of Graphite by Polyimide and Its Gas Permeability (1992). Carbon, Vol. 30, No. 3 , pp. 513-516.
Wang, X. H. and Liu, Z. The Forchheimer Equation in Two-Dimensional Percolation Porous Media (2004). Physical, Statistical and Theoretical Physics, 337(3 – 4), pp. 384 – 388.
Ammen, C. W. The Complete Handbook of Sand Casting, 1st Edition. US. (1979).
Rao, P. N. Manufacturing Technology (2001). Tata McGraw-Hill Publishing Company Limited, New Delhi.
Campbell, J. Casting. Butterwork, Heinemann (2003).
Turkeli, A. History of Metal Casting (2019). In: Lecture Notes on Foundry Technology (MSE 432).
Singer, C. J., Holmyyard, and Hall, A. R. A History of Technology. Vol. 1. Clarendon
Press, Oxford (1954).
Uobabylon. Basics of Metal Casting (1951). http://www.uobabylon.edu.iq/eprints/
Publication-1-1951-6172. Accessed on 2nd September, 2019.
MCE. Casting and Welding Technology. https://prog.lmu.edu.ng/colleges_cms/
Document/books/mce 527. Accessed on 2nd September, 2019.
Roy, R. K. Design of Experiments Using the Taguchi’s Approach (2001). New York. ISBN: 0-471-36101-1
Raghupathy, R. and Amirthagadeswaran, K. S. Parametric Optimisation and Solidification Analysis of Grey cast Pump Adapter Castings Using DOE and CAE- A Case Study (2016). http://www.tandfonline.com/loi/tmec20
Dabade, U. and Bhedasgaonkar, R. Casting Defect Analysis Using Design of Experiments (DOE) and Computer Aided Casting Simulation Technique (2013). Procedia CIRP7: 616-621.
Verran, G. O., Mendes, R. P. and Rossi, M. A. Influence of Injection Parameters on Defects Formation in Die Casting al12Sil, 3Cu alloy: Experimental Results and numeri Simulation (2006). J Mater Process Tech., 179: 190-195.
Bauer, J. T., Galetz, M. C. and Schutze, M. Corrosion-Resistant Coatings for Refractory Lining Anchors in Aggressive High Temperature Environment (2009). The German Ministry of Economics and Technology through the German Federation for Industrial Research.
Prstic, A. Pavlovic, A., Andric, L., Janovic, J. and Terzic, A. Zircon-based Coating for the Applications in Lost Foam casting Process (2012). Chemical Industry and Chemical Engineering Quarterly. 18(4): 587-593.
Prstic, A. Acimovic-Pavlovic, Z., Terzic, A. and Pavlovic, L. Synthesis and Characterization of New Refractory Coatings Based on Talc, Cordierite, Zircon and Mullite Fillers for Lost Foam Casting Process (2014). Achives of Metallurgy and Materials, 59 (1).
Omidiji, B. V., Khan, R. H., and Abolarin, M. S. Silica-Kaolin Mix Effect on Evaporative Pattern Castings Surface Roughness (2016). Archives of Foundry Engineering. 16 (3): 83-88.
Omidiji, B. V. Development of Refractory Coating Using Locally Available Silica and Kaolin for Foundry Use. Proceedings of the OAU Faculty of Technology Conference, 2017.
Aftab, A. Qureshi, M. I., Mujahid, m. and Khalid, S. Effect of different Coatings on the Surface Finish and hardness of manganese steel castings ( 2019 ).
Omidiji, B. V. Evaporative Pattern Casting (EPC) Process (2018). http: //dx. doi. Org/10.5772intechopen.73526.
Luoyang Liushi Mould Co. Ltd. Refractory Coating for Lost Foam Casting. www.is-
casting-mold.com. Accessed on 2nd September, 2019.
Holtzer, M. R., Danko, S., and Zymankowsko, K. Foundry Industry – Current State
and Future Development (2012).
Foundry - planet.com. 2025 Projection. Accessed on 30th July, 2023.
Mathov, S. Growing Demand in Various Industrial Sectors Will Offer Lucrative Opportunities for Steel Casting Industry. Allied Market Research (2022).
Nwigbo, M. N. The Foundry Industry: A Sustainable Industrialisation and Development Strategy for Nigeria (2019). International Journal of Mechanical and Civil Engineering, 2(2): 1 – 10
Patrick, O. A. and Akintunde, O. A. Determinants of Sales of Foundry Products in Nigeria: A Discriminant Function Analysis (2017). Int. J. of Adv. 5(1), 159 – 17
The American Foundrymen’s Society. Moulding Methods and Materials. 1st
Edition. Illonois (1962).
Kumar, S., Kumar, P. and Shan, H. S. Characterisation of the Refractory Coating Materials Used in Vacuum Assisted Evaporative Pattern Casting Process. Journal of Material Proceeding Technology. Vol. 209(2008); pp. 2699-2706
Kascheev, I. D., Novozhilov, N. Y., Tsarevskii, E. V., Perepelitsyn, V. A., Ryabin, V. A. and Seliverstov, N. F. Refractory Coatings for Foundry Moulds and Cores. Journal of Refractories and Ceramics, 23 (1982): 36 – 139.
Pacyniak, T. The Effect of Refractory Coating Permeability on the Lost Foam Process (2008). Archives of Foundry Engineering, 8(3): 199 - 204.
Beauvais, P., Mabilais, P. and Ribbon, A. BISI Transaction 27398 of Foundrie-Foundeur Aujour-d’hui (1988). 79(11).
Foseco. Shaping the Future with the Lost Foam Casting Process. Foundry Practice, (1999) 232: 12 - 16.
Shroyer, H. F. US Patent 2830343. (1958)
Moore, R. E. Refractories, Structure and Properties. Encyclopaedia of Materials Science and Technology (2001), pp. 8079-8099.
Pirkle, F. L. and Podmeyer, D. A. Zircon: Origin and Uses: Society for Mining, Metallurgy and Exploration, (1998), Vol. 292. http://cam. usf.edu/ CAM/exhibitions /1998_12_McCollum /supplementaldidactics/62.Zircon.pdf.
Hlavac, J. Melting Temperatures of Refractory Oxides (1982). Pure and Applied Chemistry, 54 (3): 681-688. doi:10.1351/pac198254030681
Houssa, C. E. Minerals in Plastics,” Bulletin de la Societe Royale des sciences de liege, (2003). 72:71-80.
Ulrich, G. D. and Molesky, D. W. Silica Fillers from Silicon Powder (1988). US Patent 4, 755, 368. http://www.osti.gov/energycitations/product.biblio.
Aftab, A. Qureshi, M. I., Mujahid, m. and Khalid, S. Effect of different Coatings on the Surface Finish and hardness of manganese steel castings ( 2019 ).
Yekeler, M., Ulusoy, U. and Hicyilmaz, C. Effect of Particle Shape and Roughness of Talc Mineral around by Different Mills on the Wettability and Floatability (2004). Powder Technology, 140(12), pp. 68-78.
Ariffin, K. S. Talc and Pyrophylite Group – 2:1 Phyllosilicate (2000). EBS 425 – Mineral preindustrial, pp. 1-21.
Acimovic-Pavlovic, Z. S., Prstic, A. K. and Andric, L. D.. The Characterization of Talc-Based Coating for Application for Al-Si Alloy Casting (2007). Chemical Industry and Chemical Engineering Quarterly, 13(1), pp. 38-40.
Gan, D., Lu, S., Song, C. and Wang, Z. Physical Properties of Poly(etherketone ketone)/mica composites (2001). Effects of Filler Content. 48(5): 299 – 02. https://www.sciencedirect.com. Accessed on 31st July, 2023.
Jackson, J. A. Bentonite. Glossary of Geology (Fourth ed.). Alexandria, Virginia: American Institute. ISBN 0922152349 (1997)
Pohl, W. L. Introduction to Formation and Sustainable Exploitation of Mineral Deposits. Economic Geology: Principles and Practice (2011), Chichester, West Sussex, p.331
Omidiji, B. V. Development of Refractory Coating Using Locally Available Silica and Kaolin for Foundry Use. Proceedings of the OAU Faculty of Technology Conference, 2017.
Dale, T. What is Fly Ash and how is It Used in Concrete? https://www.thespruce.com. Accessed on 24th July, 2023.
Environmental Protection Agency. Coal Ash Basics (2021).
Pursall, F. W. Coatings for Mould and Cores. K. Straus, Ed., Applied Science in the Casting of Metals, Pergamon Press, Oxford (1970). Cast TIP. Controlling Refractory Coatings (2010). Modern Casting. http://www.thefreelibrary.com
Baker, S. G. Evaluating Refractory Coatings: a Practical Approach (2002). Modern
Casting, vol. 92. Pp. 21-23.
Winardi, L. and Griffin, R. D. Effects of Coating Drying Methods on LOI, Gas Evolution and Core Permeability. AFS Transactions Paper, Vol. 08-047, 2008.
Wright, J. D. and Sommerdijk, N. A. Sol-Gel Materials Chemistry and Applications. CRC Press, London (2001).
Ramrattan, S. N. and Joyce, M. K. Final Report Refractory Coating Control (2009).
http://amc.aticorp.org
Chen, X. and Penumadu, D. Permeability Measurement and Numeri Modelling for
Refractory Porous materials (2008). Shaumburg IL: AFS Transactions, American Foundry Society, US. Unpublished.
Anderson, W. A. Permeability Relationships Using Darcy Permeability, Vacuum Decay, Pressure Decay and Pore Size Distribution Methods on Graphic Materials (1966). Carbon, 4(1): 107 – 114.
Sogabe, T., Inagaki, M. and Ibuki, T. Coating of Graphite by Polyimide and Its Gas Permeability (1992). Carbon, Vol. 30, No. 3 , pp. 513-516.
Wang, X. H. and Liu, Z. The Forchheimer Equation in Two-Dimensional Percolation Porous Media (2004). Physical, Statistical and Theoretical Physics, 337(3 – 4), pp. 384 – 388.
Ammen, C. W. The Complete Handbook of Sand Casting, 1st Edition. US. (1979).
Rao, P. N. Manufacturing Technology (2001). Tata McGraw-Hill Publishing Company Limited, New Delhi.
Campbell, J. Casting. Butterwork, Heinemann (2003).
Turkeli, A. History of Metal Casting (2019). In: Lecture Notes on Foundry Technology (MSE 432).
Singer, C. J., Holmyyard, and Hall, A. R. A History of Technology. Vol. 1. Clarendon
Press, Oxford (1954).
Uobabylon. Basics of Metal Casting (1951). http://www.uobabylon.edu.iq/eprints/
Publication-1-1951-6172. Accessed on 2nd September, 2019.
MCE. Casting and Welding Technology. https://prog.lmu.edu.ng/colleges_cms/
Document/books/mce 527. Accessed on 2nd September, 2019.
Roy, R. K. Design of Experiments Using the Taguchi’s Approach (2001). New York. ISBN: 0-471-36101-1
Raghupathy, R. and Amirthagadeswaran, K. S. Parametric Optimisation and Solidification Analysis of Grey cast Pump Adapter Castings Using DOE and CAE- A Case Study (2016). http://www.tandfonline.com/loi/tmec20
Dabade, U. and Bhedasgaonkar, R. Casting Defect Analysis Using Design of Experiments (DOE) and Computer Aided Casting Simulation Technique (2013). Procedia CIRP7: 616-621.
Verran, G. O., Mendes, R. P. and Rossi, M. A. Influence of Injection Parameters on Defects Formation in Die Casting al12Sil, 3Cu alloy: Experimental Results and numeri Simulation (2006). J Mater Process Tech., 179: 190-195.
Bauer, J. T., Galetz, M. C. and Schutze, M. Corrosion-Resistant Coatings for Refractory Lining Anchors in Aggressive High Temperature Environment (2009). The German Ministry of Economics and Technology through the German Federation for Industrial Research.
Prstic, A. Pavlovic, A., Andric, L., Janovic, J. and Terzic, A. Zircon-based Coating for the Applications in Lost Foam casting Process (2012). Chemical Industry and Chemical Engineering Quarterly. 18(4): 587-593.
Prstic, A. Acimovic-Pavlovic, Z., Terzic, A. and Pavlovic, L. Synthesis and Characterization of New Refractory Coatings Based on Talc, Cordierite, Zircon and Mullite Fillers for Lost Foam Casting Process (2014). Achives of Metallurgy and Materials, 59 (1).
Omidiji, B. V., Khan, R. H., and Abolarin, M. S. Silica-Kaolin Mix Effect on Evaporative Pattern Castings Surface Roughness (2016). Archives of Foundry Engineering. 16 (3): 83-88.
Omidiji, B. V. Development of Refractory Coating Using Locally Available Silica and Kaolin for Foundry Use. Proceedings of the OAU Faculty of Technology Conference, 2017.
Aftab, A. Qureshi, M. I., Mujahid, m. and Khalid, S. Effect of different Coatings on the Surface Finish and hardness of manganese steel castings ( 2019 ).
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Published
2024-09-07
How to Cite
Omidiji, B. V., Ajewole, R., & Oluwajobi, A. (2024). Refractory Coating Technology: A Review: Coating Technology. Ife Journal of Technology, 29(1), 49–54. Retrieved from https://ijt.ng/index.php/ijt/article/view/235
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V. Materials, Mechanics and Nanotechnology
